The vehicle:

2006 Star Classic 4+2, 48 volt

Controller:

Curtis 1244-5461

Contactor:

Albright SW80B-156

The problem:

When the key is turned on the cart won’t move and the controller blinks code 3-4, “Missing contactor”

Testing results:

Battery voltage: 48.8 volts

Contactor coil resistance: 216-222 Ω

Contactor power terminal resistance while applying B+ and ground to the contactor windings: .1 Ω

Motor field coil resistance: 1.1 Ω

Motor A1 to A2 resistance: 0.2 Ω

With the key switch on there is battery voltage at Pin 1 (KSI), Pin 9 (coil return input), one side of the contactor coil, at the Forward/Reverse selector switch, and the interlock switch at the throttle.

The wire from Pin 17 (main contactor driver output) to the control coil of the contactor has 0.1-0.2 Ω of resistance when disconnected from the controller and contactor.

What I’ve done:

I sent the controller to Cloud Electric to be tested/rebuilt. It was tested and returned with no problem found.

I re-installed the controller and as soon as the key is turned on it still flashes code 3-4.

I re-measured motor resistance, wiring resistance, contactor resistance. I un-taped the wiring and visually inspected it. I then concluded that there must still be something wrong with the controller and returned it to Cloud Electric. They returned it to me and assured me that there was nothing wrong.

Even though the contactor tested good, I purchased a new contactor. I also purchased Molex pins and made a test harness to bypass the existing harness. I still had code 3-4 and decided to buy a new controller and also purchased a 1313-4331 Programmer. The new controller also flashes code 3-4.

I solicited the help of members of Cartaholics golf cart forum and they suggested the same items that I had already been over and unfortunately they have run out of ideas.